Modular wall system for clean room structure

ABSTRACT

A modular wall system adapted for use as part of a clean room structure, comprising a plurality of unibody panel sections, each panel section having a uniform width and including an exterior face, an interior face, and laterally opposing assembly flanges extending along the length of each edge of the panel section. Each assembly flange includes (i) a flange side wall extending inward from the interior face, (ii) an interlocking member adapted to be engaged with another interlocking member of a separate panel to secure the two flanges together, and (iii) a sealing member for sealing openings between coupled assembly flanges. A support channel configured in size and shape for snug fit around the coupled assembly flanges includes a channel cap and side channel walls which extend for equal lengths sufficient to abut against the interior faces of the coupled panel sections. These side walls operate as spacer members for aligning panel sections as the assembly flanges are secured within the support channel. Gripping members are coupled between the support channel and respective interlocking members of coupled assembly flanges for securing the above elements into a single wall system, wherein the coupled assembly flanges and enclosing support channel form a rigid wall stud member.

BACKGROUND OF THE INVENTION

1. Field of Invention

This invention pertains to a modular wall system adapted for use as partof a clean room structure. More particularly, the present inventionrelates to a modular construction wherein wall panels can be quicklyassembled or disassembled, yet wherein the assembled wall structure iscapable of being sealed at the juncture of each attached wall panel todevelop a Class 10 clean room status.

2. Prior Art

Clean room structures are especially constructed enclosures whichprovide an environment free of dust and typical contaminating particleswhich are normally present in air. Such environments are required forthe manufacture of sensitive electronic components, particularlyintegrated computer chips having hundreds of tiny circuits whoseeffective operation depends upon the absence of foreign materials. Suchstructures are classified, based upon the number of particles present ina cubic foot of air space. For example, a Class 10 clean room means thatthere are only ten or less particles of 0.5 microns in size or larger ina cubic foot of air space.

The construction of such specialized structures has traditionallyrequired permanent construction techniques which offered littleflexibility in terms of structural modifications in disassembly. Suchpermanent construction was believed necessary in order to develop theairtight enclosure required to meet clean room standards.

U.S. Pat. No. 4,667,579 discloses a modular construction which meets thestringent, airtight standards for a clean room but provides flexibilityin disassembly and modification to variable structural configurations. Aprinciple characteristic of the disclosed clean room includes thecomponents and techniques for attaching a vertical strut or stud at thejuncture of two panel elements in a manner such that complete sealingagainst particle infiltration was accomplished. These techniquesincluded the use of a conventional steel stud which was slotted toreceive a clip, wherein the mated clip was attachable to lateral flangesof two abutting panel sections. Such a configuration is shown in FIGS. 4and 5 of the referenced patent.

Although such structure represented a significant improvement over priorart methods and apparatus for construction of modular clean roomassemblies, tolerances of each component allowed a degree ofmisalignement which necessitated careful attention during assembly.Although careful construction techniques have traditionally beenrequired in fabricating clean room structures, it would be a substantialimprovement in the art if clean room structural components wereself-adjusting to establish coalignment of panel sections within thesingle plane and complete sealing of panel junctures.

The concept of utilizing lateral flanges on separate panel sections isnot unique to clean room construction. For example, U.S. Pat. No.4,649,684 by Petree shows a panel section which includes lateral flangescapable of being clipped together by a channeled chip which enclosed aresulting "T" configuration formed by the abutting lateral flanges.Other techniques for structurally interlocking panel sections arerepresented in U.S. Pat. No. 4,461,131 by Pressell, U.S. Pat. No.2,867,857 by McCarthy and U.S. Pat. No. 3,975,880 by Fischer, Jr. Noneof these patents, however, provides structure suitable for clean roomconstruction wherein they are adapted to seal at the panel juncture anddevelop the level of parallel alignment which is needed to ensure fullstructural integrity in accordance with clean room specifications.

OBJECTS AND SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide a modularwall system which is capable of quick assembly wherein wall panelsections are automatically aligned along panel faces and at the abuttinglateral flanges.

A further object of the present invention is to provide such a modularwall assembly wherein the panel junctures are easily sealed to meetclean room specifications.

A still further object of this invention is to provide a modular wallsystem in which lateral flanges of panel sections can be interlocked toform a wall stud providing reinforcement to the assembled wallstructure.

Yet another object of this invention is to provide a modular wall systemwhich meets clean room specifications, can be quickly assembled toinclude integrated wall stud structure, wherein the wall stud structureincludes longitudinal channeling for running conduit for wiring andsimilar construction materials.

These and other objects are realized in a modular wall system which isadapted for use as part of a clean room structure wherein the wallsystem includes a unibody panel section of uniform width which isadapted for interlocking relationship with other panel sections to forman enclosing wall structure. Each panel section includes an exteriorface, an interior face and laterally opposing assembly flanges whichextend along the length of each edge of the panel sections. Theseassembly flanges are configured to be interlocked when panel sectionsare brought in common, side-by-side orientation wherein the interlockedflanges form a stud member for the wall system. The assembly flangesinclude (i) a flange side wall extending inward from the interior faceof the panel to a distal edge of the side wall, (ii) an interlockingmember coupled to the side wall and including means for secure fasteningwith respect to another interlocking member of an assembly flange for anadjoining panel section, and (iii) a sealing member including means forsealing openings between coupled assembly flanges. The interlockingflanges are enclosed by a support channel which is configured in sizeand shape for a snug fit around the coupled assembly flanges. Side wallsof the support channel are structurally configured to operate as spacermembers of equal length for aligning the panel sections in a commonplane when a gripping means is applied between the support channel andthe respective interlocking assembly flanges. The gripping means isstructured such that its engagement and tightening with respect to thechannel and enclosed flanges three conditions are developed. First, therespective side channel walls of the support channel are brought intoabutting contact against the interior face of each respective panelsection. Second, the coupled assembly flanges are rigidly secured withthe channel to form a single stud member which provides vertical andtransverse strength to coupled panel sections. Finally, the sealingmembers of each assembly flange are cooperatively engaged to provide asealed juncture between each interlocking panel section.

Other objects and advantages of the present invention will be apparentto those skilled in the art, based upon the following detaileddescription, taken in combination with the accompanying drawings.

DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a perspective partial view of two panel sections joined attheir abutting assembly flanges with an enclosing support channelrigidly fixed in position.

FIG. 2 shows an end view of an alternative embodiment of interlockingassembly flanges enclosed by the support channel.

FIG. 3 discloses a third embodiment wherein the sealing member isadapted with spacing guide to further ensure correct alignment of thecoupled panel sections.

FIG. 4 is a perspective view of a panel section embodying the featuresof the present invention.

DETAILED DESCRIPTION OF THE INVENTION Referring now to the drawings:

FIG. 1 discloses lateral end sections of two coupled panel sections 10and 11. These panel sections 10 and 11 abut at juncture 12 at the pointof attachment of laterally opposing assembly flanges 13 and 14. Theabutting assembly flanges are enclosed within a support channel 15 whichis interlocked with the assembly flanges by means of a nut 16 havingslotted spacer channels 17 and an engaging bolt 18. These interlockingcomponents including the assembly flanges 13 and 14, the support channel15 and gripping means 16 and 18 are mutually assembled and engaged todevelop a stud member which provides strength both vertically and intraverse orientation for an assembled modular wall system.

More specifically, each panel section 10 and 11 is constructed with auniform width of a basic unitary dimension. For example, the panelsection shown in FIG. 4 may be a one-foot, two-foot or one-yard sectionor comparable metric measurements which can be utilized to develop atotal wall section of appropriate dimension by interlocking variousunitary panel sections to realize the total width desired. The length ofeach panel section may vary and will be determined based on the heightof the wall system required as well as locations of equipment ports atvarious positions along the wall system.

Each panel section 10 and 11 includes an interior face 20 and anexterior face 21. Typically, the exterior face 21 will form a planersurface which provides interior wall structure to the clean roomassembly. The interior surface 20 may include structural reinforcingribs 22 which typically run the total height of the panel section.

The assembly flanges 13 and 14 are constructed in uniform configurationto enable their common attachment with assembly flanges of other panels.Each assembled flange includes a flange side wall 23 which extendsinward from the interior face 20 of the panel section to a distal edge24, which is attached to an interlocking member 25 which provides meansfor a secure fastening of the assembly flange 14 with respect to anotherinterlocking member of a comparable assembly flange on a second panelsection.

The assembly flange 14 also includes a sealing member 26 having means 27for sealing openings 28 between the coupled assembly flanges 13 and 14.Typically, this sealing means 27 comprises a flowable liquid such as agel caulking capable of totally filling the sealing opening 28 as a fullbarrier against particle transmission through any gaps existing at thejuncture 12 of the respective panels 10 and 11.

It will be apparent to those skilled in the art that each of these threecomponents 23, 25 and 26 of the assembly flange may be formed in variousconfigurations. For comparison purposes, the flange configuration shownin FIG. 1 is referred to as an inverted "5" shape wherein the verticalstem of the "5" represents the flange sealing member 26 with theattached horizontal member of the "5" shape comprising lateral segment29 of the panel section and the vertical section of the squared "c"element of the "5" comprising the side wall 23 with joined horizontalelements 25 and 30. This "c" shape is more clearly represented by thebroken line "c" 31. It will be noted that in this configuration, the top"c" shape forms part of the interlocking member, with the top terminalend 32 being operable to interlock with a corresponding terminal end 33of adjoining flange 13. It should be noted that the sealing member 26includes a notched section 28 which provides the sealing opening forreceiving sealing means 27 within a resulting channel formed by thejunction of corresponding notches 28 on each respective flange.

FIG. 2 shows an alternate embodiment of the assembly flange which isconfigured as a squared "J". In this embodiment, the sealing member 34includes one-half of the top, flat part of the inverted "J" 35 whichcouples centrally to the vertical stem 37, which element corresponds tothe side wall 14 of FIG. 1. This side wall 37 or vertical stem of the"J" extends upward to the hook element of the "J", identified as item38. This inverted "J" configuration is illustrated in hyphen line 39 forcomparison purposes. The hook element 38 forms part of the interlockingmember which functions similarly to element 25 and 32 of the assemblyflange configuration in FIG. 1. More specifically, the hook element ofthe "J" comprises a flat section 40 which is substantially parallel withthe panel section 42 and 43 and is attached at a top end of the stem 37.The hooked end of the "J" further includes a vertical leg 44, whichcorresponds to element 32 of FIG. 1. This vertical leg 44 seats within agroove 45 of the gripping means nut 46 engaged by the gripping meansbolt 47. The sealing member of the "J" configuration comprises one-half48 of the top, flat part 35 of the "J". This half segment 48 extendsfrom the stem 37 to a proximate, distal side 49 of the panel section.The sealing opening 50 is formed by opposing channel walls 51 and 52. Asealing fluid 53 is loaded within the opening 50 to provide the desiredbarrier against particle intrusion.

It should be noted that the width of the sealing member 48 is greaterthan the width 54 of the hooked element of the "J". This results in agap 55 between vertical legs 44 and 56. This gap provides an openingthrough which the gripping mold 47 may extend from the support channel58.

Referring again to FIGS. 1 and 2, the support channel 58 is configuredin size and shape for a snug fit around the coupled assembly flanges13/14 and 37a/37b. This channel includes a channel cap 60 and sidechannel walls 61 and 62 which extend for equal lengths sufficient toabut against the interior faces 63 and 64 of the coupled panel sections.In this configuration, the channel walls 61 and 62 operate as spacermembers of equal length for aligning the panel sections 10 and 11, 42and 43. This spacer function is automatically imposed as the grippingmeans 16 and 18, 47 and 47 are engaged. Specifically, the assemblyflange structure and the support channel are configured in size suchthat the gripping means pulls the assembly flanges toward the supportchannel cap 60, thereby driving the support channel side walls 61 and 62toward the interior faces 63 and 64 of the panel sections. Because theseside walls 61 and 62 are of equal length, the panel sections are broughtinto common, planer orientation when the gripping means is fullysecured.

The flange assembly structure is properly sized to snugly fit within thesupport channel structure as is shown in the figures. The spacer orseating channels 17 (FIG. 1) and 45 (FIG. 2) receive the terminal ends32 and 56 of the vertical legs for the respective assembly flanges.These seating channels are exactly spaced apart and chamfered at sidewalls to properly align the interlocking members 25 or 38 in theattached assembly flange structure. It will be apparent to those skilledin the art that other forms of gripping means can be envisioned besidesthe nut and bolt combination as shown in the figures. For example, alatch assembly could be alternated for the nut and bolt combination,wherein the latch extends upward through the support channel and permitslever action to engage an aligning element such as shown in FIGS. 1 and2 as items 16 and 46.

In view of the foregoing description, it will now become apparent thatthree conditions are satisfied as the gripping means are engaged andsecured to their locked position. Specifically, as the gripping meanspulls the support channel 58 in the coupled assembly flanges 13/14 and37a/37b into nesting configuration, (i) the respective channel sidewalls 61 and 62 of the support channel are firmly abutting against theinterior faces 63 and 64 of the panel sections. Also, the coupledassembly flanges are rigidly secured with the channel 58 to form asingle stud member which provides vertical and transverse strength tothe coupled panel sections. Finally, the sealing members 26 and 52/57are cooperatively engaged to provide a sealed juncture 27 and 53 betweenthe respective panel sections.

This fully secured condition may be enhanced by use of projecting guideflanges 70 which are aligned in substantial parallel orientation withthe assembly flanges and are displaced slightly inward along theinterior face of the panel to properly position the side channels 61 and62 in tight fit between the single flange and the guide flanges 70.

FIG. 3 discloses an additional spacer guide assembly which is configuredas part of the sealing member. Specifically, a "U" shaped supportchannel 80 is shown engaged around a pair of "J" shaped assembly flanges81 and 82. The sealing member of assembly flange 81 is identified asitem 83 which extends over width 84. Similarly, sealing member 85 offlange 82 extends over width 86. Each respective sealing member includesa notch 87 and 88 and engaging tooth 89 and 90. As the nut 91 and bolt92 are secured in a seated position, the respective teeth of the sealingmembers 83 and 85 seat in corresponding notches, further securing theproper alignment of the assembly flanges. A sealing opening 93 retains asealing gel in accordance with previous description. This configurationfurther operates to retain the sealing member in firm, sealing contact.

FIG. 4 illustrates a sample wall section 100 which includes an exteriorface 101 and interior 102. Opposing assembly flanges 103 and 104 providemeans for interlocking each panel section to an adjacent panel sectionin common, planer configuration. The description of such assemblyflanges has been adequately presented in previous discussion. Aplurality of such panels 100 are secured together in side-by-side arrayto form a wall structure, which is capable of operating within the cleanroom specifications previously described. In addition to providing wallstructure, the assembly flanges include conduit channels 104, 105, 106and 107 which facilitate protective enclosure of electrical conduit,telephone line, etc.

In view of the foregoing description, it will be apparent to thoseskilled in the art that numerous advantages arise because of thecomponent structure. Specifically, the complex construction of cleanroom wall structure has now been reduced to three simple components.First is a single panel section 100 which already includes the opposingassembly flanges 103 and 104. Such panel structure and support channelmay be fabricated by extrusion, using composition such as polymers,aluminium, composites or other suitable materials. Such panel sections100 are quickly assembled by bringing two panel sections inapproximately co-planer alignment with the assembly flanges in abuttingconfiguration. A sealing composition such as silicone or some other formof caulking gel is loaded within the sealing opening 28 and the supportchannel 58 with gripping means 17/18 is positioned around the abuttingassembly flanges. By tightening the gripping means 18, panel walls areautomatically aligned in co-planer relationship with the junction 12 ofthe two panels being fully sealed by the loaded sealing composition 27.Accordingly, the complex prior art process of constructing a clean roomwall system is now reduced to several simple steps which automaticallyresult in proper alignment and sealing of wall junctures.

It will be apparent to those skilled in the art that the presentdisclosure is merely by way of example, and is not to be construed aslimiting upon the following claims.

We claim:
 1. A modular wall system adapted for use as part of a cleanroom structure wherein the wall system is capable of developing a Class10 clean room status, said system comprising:(a) a unibody panel sectionof uniform width and variable length, said section including (i) anexterior face, (ii) an interior face, and (iii) laterally opposingassembly flanges extending along the length of each edge of the panelsection which can be interlocked with a comparable assembly flange of asecond unibody panel section brought in common, side-by-side orientationwith the first panel section, the interlocked flanges cooperating toform part of a single reinforcing stud member for the wall system; (b)said assembly flanges each including (i) a flange side wall extendinginward from the interior face of the panel section (ii) an interlockingmember coupled to the flange side wall and including means for securefastening with respect to another interlocking member of an assemblyflange for the second panel section, and (iii) a sealing memberincluding means for sealing openings between coupled assembly flanges,said assembly flanges each being configured in an inverted "J" shapewith the lower, hooked element of the "J" forming the interlockingmember and the top of the "J" forming part of the sealing member, thehooked element and top being joined by a vertical stem to complete the"J" configuration; (c) a support channel configured in size and shapefor a snug fit around the coupled assembly flanges, said channelincluding (i) a channel cap and (ii) side channel walls which extend forequal lengths sufficient to abut against the interior faces of thecoupled panel sections, said side channel wall being operable as spacermembers of equal length for aligning the panel sections in a commonplane; and (d) gripping means coupled between the support channel andthe respective interlocking members of the coupled assembly flanges forgripping the coupled assembly flanges in a configuration in which (i)the respective side channel walls of the support channel are firmlyabutting against the interior faces of coupled panel sections, (ii) thecoupled assembly flanges are rigidly secured with the channel to form asingle stud member which provides vertical and transverse strength tothe coupled panel sections, and (iii) the sealing members of eachassembly flange are cooperatively engaged to provide a sealed juncturebetween the respective panel sections.
 2. A modular wall as defined inclaim 1, wherein the gripping means comprises a nut and bolt, said boltbeing mounted at an exterior face of the channel support and extendingtherethrough and between the interlocking member, said nut includingspacer means for correctly spacing the vertical legs as the grippingmeans is engaged, as well as developing the required structuralrelationships (i) to (iii) defined for the gripping means.
 3. A modularwall as defined in claim 2, wherein the spacer means comprises a pair ofseating channels configured to receive terminal ends of the verticallegs of two coupled assembly flanges, said seating channels beingcorrectly spaced apart to thereby properly align the end pieces of thevertical legs and attached assembly flanges as they seat within theseating channels.
 4. A modular wall system adapted for use as part of aclean room structure wherein the wall system is capable of developing aClass 10 clean room status, said system comprising:(a) a unibody panelsection of uniform width and variable length, said section including (i)an exterior face, (ii) an interior face, and (iii) laterally opposingassembly flanges extending along the length of each edge of the panelsection which can be interlocked with a comparable assembly flange of asecond unibody panel section brought in common, side-by-side orientationwith the first panel section, the interlocked flanges cooperating toform part of a single reinforcing stud member for the wall system; (b)said assembly flanges each including (i) a flange side wall extendinginward from the interior face of the panel section (ii) an interlockingmember coupled to the flange side wall and including means for securefastening with respect to another interlocking member of an assemblyflange for the second panel section, and (iii) a sealing memberincluding means for sealing openings between coupled assembly flanges,each of said flange assemblies being configured in the shape of aninverted "5" with the lower, vertical stem of the "5" forming part ofthe sealing member and the top "c" configuration of the "5" forming partof the interlocking member, the top terminal end of the "c" beingoperable to interlock with the corresponding terminal end of a "c" of anadjoining assembly flange; (c) a support channel configured in size andshape for a snug fit around the coupled assembly flanges, said channelincluding (i) a channel cap and (ii) side channel walls which extend forequal lengths sufficient to abut against the interior faces of thecoupled panel sections, said side channel wall being operable as spacermembers of equal length for aligning the panel sections in a commonplane; and (d) gripping means coupled between the support channel andthe respective interlocking members of the coupled assembly flanges forgripping the coupled assembly flanges in a configuration in which (i)the respective side channel walls of the support channel are firmlyabutting against the interior faces of coupled panel sections, (ii) thecoupled assembly flanges are rigidly secured with the channel to form asingle stud member which provides vertical and transverse strength tothe coupled panel sections, and (iii) the sealing members of eachassembly flange are cooperatively engaged to provide a sealed juncturebetween the respective panel sections.
 5. A modular wall system asdefined in claim 4, wherein the sealing member includes a sealingchannel formed by abutment of corresponding notches formed in respectivestems of the flange assembly, said channel being operable to receive asealing fluid therein.
 6. A modular wall system adapted to use as partof a clean room structure wherein the wall system is capable ofdeveloping a Class 10 clean room status, said system comprising:(a) aunibody panel section of uniform width and variable length, said sectionincluding (i) an exterior face, (ii) an interior face, and (iii)laterally opposing assembly flanges extending along the length of eachedge of the panel section which can be interlocked with a comparableassembly flange of a second unibody panel section brought in common,side-by-side orientation with the first panel section, the interlockedflanges cooperating to form part of a single reinforcing stud member forthe wall system; (b) said assembly flanges each including (i) a flangeside wall extending inward from the interior face of the panel section(ii) an interlocking member coupled to the flange side wall andincluding means for secure fastening with respect to anotherinterlocking member of an assembly flange for the second panel section,and (iii) a sealing member including means for sealing openings betweencoupled assembly flanges; (c) a support channel configured in size andshape for a snug fit around the coupled assembly flanges, said channelincluding (i) a channel cap and (ii) side channel walls which extend forequal lengths sufficient to abut against the interior faces of thecoupled panel sections, said side channel wall being operable as spacermembers of equal length for aligning the panel sections in a commonplane; (d) gripping means coupled between the support channel and therespective interlocking members of the coupled assembly flanges forgripping the coupled assembly flanges in a configuration in which (i)the respective side channel walls of the support channel are firmlyabutting against the interior faces of coupled panel sections, (ii) thecoupled assembly flanges are rigidly secured with the channel to form asingle stud member which provides vertical and transverse strength tothe coupled panel sections, and (iii) the sealing members of eachassembly flange are cooperatively engaged to provide a sealed juncturebetween the respective panel sections, and (e) a guide flange projectingin parallel orientation with the assembly flange and displaced slightlyinward along the interior face of the of the panel section to properlyposition the side channel walls in tight fit between the assembly flangeand the guide flange.